Upflow condensate drain pan

ABSTRACT

A condensate drain pan including a drain pan panel, including a panel interior side and a panel exterior side, a channel member formed on the panel exterior side, a front wall, a rear wall, and opposing side walls. The front wall, rear wall and opposing side walls extend from the drain pan panel to form a receptacle, and the front wall includes a first aperture and a second aperture in the front wall.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is related to, and claims the priority benefitof, U.S. Provisional Patent Application Ser. No. 61/910,810 filed Dec.2, 2013, the contents of which are hereby incorporated in their entiretyinto the present disclosure.

TECHNICAL FIELD OF THE DISCLOSED EMBODIMENTS

The presently disclosed embodiments generally relate to appliances forheating and cooling air, and more particularly, to an upflow condensatedrain pan.

BACKGROUND OF THE DISCLOSED EMBODIMENTS

In a conventional refrigerant cycle, a compressor compresses arefrigerant and delivers the compressed refrigerant to a downstreamcondenser. From the condenser, the refrigerant passes through anexpansion device, and subsequently, to an indoor. The refrigerant fromthe indoor is returned to the compressor. In a split system heatingand/or cooling system, the condenser may be known as an outdoor heatexchanger and the indoor as an indoor heat exchanger, when the systemoperates in a cooling mode. In a heating mode, their functions arereversed.

In the split system, the indoor may be part of a fan coil assembly. Atypical fan coil assembly includes an indoor coil (e.g., a coil shapedlike a “V”, which is referred to as a “V-coil”) and a condensate drainpan disposed within a casing. A V-coil may be referred to as a“multi-poise” coil because it may be oriented either horizontally orvertically in the casing of the fan coil assembly.

During a cooling mode operation, a blower circulates air through thecasing of the fan coil assembly, where the air cools as it passes overthe indoor coil. The blower then circulates the air to a space to becooled. Depending on the particular application, a fan coil assemblyincluding a vertically oriented V-coil may be an upflow arrangement.

Typically, a refrigerant is enclosed in piping that is used to form theindoor coil. If the temperature of the indoor coil surface is lower thanthe dew point of air passing over it, the indoor coil removes moisturefrom the air. Specifically, as air passes over the indoor coil, watervapor condenses on the indoor coil. The condensate drain pan of theindoor assembly collects the condensed water as it drips off of theindoor coil, or runs along the surface of the indoor coil. The collectedcondensation then typically drains out of the condensate drain panthrough at least one of two drain holes in the condensate drain pan.Typically, the drain holes are oriented in a substantially verticalorientation to accommodate the primary drainage and an overflowdrainage. The substantially vertical orientation increases the overallsize of the condensate drain pan; thus, this orientation may increasethe size and cost of the fan coil assembly. There is, therefore, a needfor a smaller sized condensate drain pan.

SUMMARY OF THE DISCLOSED EMBODIMENTS

In one aspect, a condensate drain pan configured to contain a portion ofa coil is provided. In one embodiment, the condensate drain pan includesa front wall, a rear wall, and opposing side walls extending from adrain pan panel, including a panel interior side and a panel exteriorside, to form a receptacle. In one embodiment, the front wall includes afront wall longitudinal axis, a first aperture, and a second aperture.The first aperture and the second aperture include an aperture axis thatforms an angle less than 90 degrees with the front wall longitudinalaxis. In one embodiment, at least a portion of the opposing side wallsinclude a curvature biased towards the drain pan surface. In oneembodiment, the curvatures may be adjacent to the drain pan surface. Inat least one embodiment a channel member may be formed on the panelexterior side. In at least one embodiment, the channel member may belongitudinally disposed on the panel exterior side. In at least oneembodiment, the channel member may be substantially centered on alongitudinal axis on the panel exterior side.

In one aspect, a fan coil assembly is provided. In one embodiment, thefan coil assembly includes a coil, including a first coil slab and asecond coil slab, disposed within a casing. The fan coil assemblyfurther includes the condensate drain pan positioned to receive at leasta portion of condensate that may drip from the coil. In one embodiment,a first space may be created between an edge of the first coil slab andone of the opposing side walls, and a second space may be createdbetween an edge of the second coil slab and the other opposing sidewall. In one embodiment, the first space and the second space include afirst dimension less than or equal to approximately 0.375 inch.

In one embodiment, a third space may be created between an end of thefirst coil slab and a top edge of one of the opposing side walls, and afourth space may be created between an end of the second coil slab and atop edge of the other opposing wall. In one embodiment, the third spaceand the fourth space include a second dimension less than or equal toapproximately 0.750 inch.

In one embodiment, the fan coil assembly further includes a fan disposedwithin the casing. In one embodiment, the fan coil assembly furtherincludes an auxiliary heating assembly operably coupled to the casing.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments and other features, advantages and disclosures containedherein, and the manner of attaining them, will become apparent and thepresent disclosure will be better understood by reference to thefollowing description of various exemplary embodiments of the presentdisclosure taken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a perspective view of an upflow condensate drain according toat least one embodiment of the present disclosure;

FIG. 2 is a front view of an upflow condensate drain according to atleast one embodiment of the present disclosure;

FIG. 3 is a bottom view of an upflow condensate drain according to atleast one embodiment of the present disclosure;

FIG. 4 is a front view of a fan coil assembly according to at least oneembodiment of the present disclosure;

FIG. 5 is a cross-sectional view of the condensate drain pan positionedto receive at least a portion of condensate that may drip from a coilaccording to at least one embodiment of the present disclosure;

FIG. 6 is a schematic component diagram of an HVAC system according toat least one embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE DISCLOSED EMBODIMENTS

For the purposes of promoting an understanding of the principles of thepresent disclosure, reference will now be made to the embodimentsillustrated in the drawings, and specific language will be used todescribe the same. It will nevertheless be understood that no limitationof the scope of this disclosure is thereby intended.

FIG. 1 illustrates a condensate drain pan configured to contain aportion of a coil (not shown), the condensate drain pan generallyreferenced at 10. The condensate drain pan 10 includes a drain pan panel12, including a panel interior side 16 and a panel exterior side 18(shown in FIG. 3), a front wall 20, a rear wall 22, and opposing sidewalls 24 and 26. The front wall 20, rear wall 22, and opposing sidewalls 24 and 26 extend from the drain pan panel 12 to form a receptaclebeing operable to collect condensate. It will be appreciated that thecondensate drain pan 10 may be constructed of any durable material tocollect condensate; for example, molded plastic to name one non-limitingexample.

FIG. 2 illustrates a front view of the condensate drain pan 10 accordingto at least one embodiment. In at least one embodiment, the front wall20 includes a front wall longitudinal axis 28, a first aperture 30 and asecond aperture 32. The first aperture 30 and the second aperture 32 areconfigured to drain condensate from the panel interior side 16. Thefirst aperture 30 and the second aperture 32 include an aperture axis 34that forms an angle 36 less than 90 degrees with the front walllongitudinal axis 28. The first aperture 30 may be configured tofunction as a primary drain of condensate, and the second aperture 32may be configured to function as an overflow drain of condensate. In oneembodiment, at least a portion of the opposing side walls 24 and 26include a respective curvature 38 and 40 biased towards the drain panpanel 12. In one embodiment the curvatures 38 and 40 may be adjacent tothe drain pan panel 12. In one embodiment, as the opposing side walls 24and 26 extend longitudinally from the front wall 20 to the rear wall 22,the respective curvatures 38 and 40 are gradually reduced to formrespective substantially straight sections 39 and 41 to aid in funnelingcondensation towards the first aperture 30 and the second aperture 32.

FIG. 3 illustrates a bottom view of the condensate pan 10 according toat least one embodiment. In at least one embodiment, a channel member 42may be formed on the panel exterior side 18. In at least one embodiment,the channel member 42 may be longitudinally formed on the panel exteriorside 18. In at least one embodiment, the channel member 42 may besubstantially centered on a longitudinal axis of the panel exterior side18. The channel member 42 may be configured for engaging a mountingbracket to install the condensate drain pan 10 within a fan coilassembly, later explained herein.

FIG. 4 illustrates a front view of a fan coil assembly, generallyreferenced at 50. The fan coil assembly 50 includes a casing 52, and acoil 54, including a first coil slab 56 and a second coil slab 58,disposed within the casing 52. The coil 54 may be configured to allow aliquid to flow therethrough when responding to a demand for conditioningan interior space. The coil 54 may be composed of copper or aluminum,and arranged in a tube and fin configuration, to name just a fewnon-limiting examples. It will be appreciated that the coil 54 mayinclude any suitable number of rows of tubes, for example, two or threeto name two non-limiting examples. The fan coil assembly 50 includes thecondensate drain pan 10 positioned to receive at least a portion ofcondensate that may drip from the coil 54. In one embodiment, the fancoil assembly 50 further includes a fan 60, disposed within the casing52, configured to circulate air through the fan coil assembly 50. Fan 60may be a brushless direct-current powered axial fan, to name just onenon-limiting example. In one embodiment, the fan coil assembly 50further includes an auxiliary heating assembly 62 affixed to the casing52. It will also be appreciated that the auxiliary heating assembly 62may be disposed within the casing 52. The auxiliary heating assembly 62may be configured to provide supplemental heat to an interior space. Forexample, the auxiliary heating assembly 62 may be a nickel chromiumconductive wire or a secondary heating coil configured to allow heaterwater to flow therethrough to name a couple of non-limiting examples.

In at least one embodiment, the fan coil assembly 50 includes acondensate pan mounting bracket 64 disposed within the casing 52. In atleast one embodiment, the condensate pan mounting bracket 64 may bedisposed below the fan 60. In at least one embodiment, the condensatepan mounting bracket 64 may be substantially horizontally centered inthe casing 52. In at least one embodiment, the channel member 42 mayengage the condensate pan mounting bracket 64 to enable installation ofthe coil 54 within the fan coil assembly 50. It will be appreciated thatby placing the condensate pan mounting bracket 60 substantiallyhorizontally centered in the casing 52, the coil 54 may be easilyinserted and removed from the casing 52 for maintenance and service. Itwill also be appreciated that by placing the condensate pan mountingbracket 64 substantially horizontally centered in the casing 54, airflowproduced by fan 60 may be evenly distributed across the first and secondcoil slabs 56 and 58.

FIG. 5 illustrates a cross-sectional view of the condensate drain pan 10positioned to receive at least a portion of condensate that may dripfrom the coil 54. In at least one embodiment, a first space 66 may becreated between an edge 68 of the first coil slab 56 and a top edge 78of the opposing wall 24, and a second space 70 may be created between anedge 72 of the second coil slab 58 and a top edge 84 of the opposingwall 26. In one embodiment, the first space 66 and the second space 70include a first dimension less than or equal to approximately 0.375inch. For example, to minimize the size of the condensate drain pan 10,provide adequate space for condensate drainage, and to optimize airflowacross the first coil slab 56 and second coil slab 58, the top edges 78and 84 of the opposing walls 24 and 26 respectively, may extend nofarther than 0.375 inch from the edges 68 and 72 of the first coil slab56 and the second coil slab 58, respectively. It will be appreciatedthat the first dimension may be greater than 0.375 inch in otherembodiments.

In one embodiment, a third space 74 may be created between an end 76 ofthe first coil slab 56 and a top edge 78 of the opposing wall 24, and afourth space 80 may be created between an end 82 of the second coil slab58 and a top edge 84 of the opposing wall 26. In one embodiment, thethird space 74 and the fourth space 80 include a second dimension lessthan or equal to approximately 0.750 inch. For example, to maximize theamount of airflow exposure to the coil 54, it may be desired for theopposing walls 24 and 26 of the condensate drain pan 10 to cover no morethan 0.750 inch from the bottom ends 76 and 82 of the coil 54. It willbe appreciated that the second dimension may be greater than 0.750inches in other embodiments.

FIG. 6 illustrates an embodiment of a heating, ventilation, and airconditioning (“HVAC”) system, generally indicated at 90. The HVAC system90 includes a fan coil assembly 50 operably coupled to a heat pump 92,wherein the fan coil assembly 50 includes a condensate drain pan 10positioned to receive at least a portion of condensate that may dripfrom a coil 54. The HVAC system 90 may be configured to provide heatingand cooling within an interior space.

It will be appreciated that the condensate drain pan 10 includes achannel member 42 formed on the a panel exterior side 18 to enableeasier insertion and removal of the coil 54 from the fan coil assembly50 for maintenance and service.

While the invention has been illustrated and described in detail in thedrawings and foregoing description, the same is to be considered asillustrative and not restrictive in character, it being understood thatonly certain embodiments have been shown and described and that allchanges and modifications that come within the spirit of the inventionare desired to be protected.

What is claimed is:
 1. A condensate drain pan, configured to contain aportion of a coil, comprising: a drain pan panel, including a panelinterior side and a panel exterior side; a channel member formed on thepanel exterior side; a front wall; a rear wall; and opposing side walls;wherein the front wall, rear wall and opposing side walls extend fromthe drain pan panel; wherein the front wall includes a first apertureand a second aperture formed therein.
 2. The condensate drain pan ofclaim 1, wherein at least a portion of the opposing side walls include acurvature.
 3. The condensate drain pan of claim 2, wherein the curvatureis adjacent to the drain pan surface.
 4. The condensate drain pan ofclaim 1, wherein the channel member is longitudinally disposed on thepanel exterior side.
 5. The condensate drain pan of claim 4, wherein thechannel member is substantially centered on a longitudinal axis of thepanel exterior side.
 6. A fan coil assembly comprising: a casing; a coildisposed within the casing, wherein the coil comprises a first coil slaband a second coil slab, and wherein the first coil slab and the secondcoil slab are configured to form an apex; a condensate drain panpositioned to receive at least a portion of condensate that may dripfrom the coil, wherein the condensate drain pan comprises: a drain panpanel, including a panel interior side and a panel exterior side; achannel member formed on the panel exterior side; a front wall; a rearwall; and opposing side walls; wherein the front wall, rear wall andopposing side walls extend from the drain pan panel; wherein the frontwall includes a first aperture and a second aperture formed therein. 7.The fan coil assembly of claim 6, further comprising a fan disposed inthe casing.
 8. The fan coil assembly of claim 6, further comprising anauxiliary heating assembly affixed to the casing.
 9. The fan coilassembly of claim 6, wherein the opposing side walls include acurvature.
 10. The fan coil assembly of claim 9, wherein the curvatureis adjacent to the drain pan surface.
 11. The fan coil assembly of claim6, wherein the channel member is longitudinally disposed on the panelexterior side.
 12. The fan coil assembly of claim 11, wherein thechannel member is substantially centered on a longitudinal axis of thepanel exterior side.
 13. The fan coil assembly of claim 6, wherein afirst space is created between an edge of the first coil slab and one ofthe opposing side walls, and a second space is created between and edgeof the second coil slab and the other of the opposing side walls. 14.The fan coil assembly of claim 13, wherein the first space and thesecond space comprises a first dimension less than or equal toapproximately 0.375 inch.
 15. The fan coil assembly of claim 6, whereina third space is created between an end of the first coil slab and oneof the opposing side walls, and a fourth space is created between an endof the second coil slab and the other of the opposing side walls. 16.The fan coil assembly of claim 15, wherein the third space and thefourth space comprises a second dimension less than or equal toapproximately 0.750 inch.
 17. An HVAC system comprising: a fan coilassembly operably coupled to heat pump, wherein the fan coil assemblycomprises: a coil, wherein the coil comprises a first coil slab and asecond coil slab, and wherein the first coil slab and the second coilslab are configured to form an apex, and a fan disposed in a casing; acondensate drain pan positioned to receive at least a portion ofcondensate that may drip from the coil, wherein the condensate drain pancomprises a drain pan panel, including a panel interior side and a panelexterior side; a channel member formed on the panel exterior side; afront wall; a rear wall; and opposing side walls; wherein the frontwall, rear wall and opposing side walls extend from the drain pan panel;wherein the front wall includes a first aperture and a second apertureformed therein.
 18. The HVAC system of claim 17, wherein at least aportion the opposing side walls include a curvature.
 19. The HVAC systemof claim 18, wherein the curvature is adjacent to the drain pan surface.20. The HVAC system of claim 17, further comprising an auxiliary heatingassembly affixed to the casing.
 21. The HVAC system of claim 17, whereinthe channel member is longitudinally disposed on the panel exteriorside.
 22. The HVAC system of claim 21, wherein the channel member issubstantially centered on a longitudinal axis of the panel exteriorside.
 23. The HVAC system of claim 17, wherein a first space is createdbetween an edge of the first coil slab and one of the opposing sidewalls, and a second space is created between and edge of the second coilslab and the other of the opposing side walls.
 24. The HVAC system ofclaim 23, wherein the first space and the second space comprises a firstdimension less than or equal to approximately 0.375 inch.
 25. The HVACsystem of claim 17, wherein a third space is created between an end ofthe first coil slab and one of the opposing side walls, and a fourthspace is created between an end of the second coil slab and the other ofthe opposing side walls.
 26. The HVAC system of claim 25, wherein thethird space and the fourth space comprises a second dimension less thanor equal to approximately 0.750 inch.